WUXI KIPOR POWER PRODUCTS CO., LTD.

IG3000/IG3000E SHOP MANUAL EPA/CARB/CETL Certified Models

Kipor Power Systems, Inc. Revision 6 July, 2011

Preface
This manual covers the construction, function and servicing procedure of for the Kipor IG3000 generator. It is applicable to EPA, CARB, and CETL certified models. An appendix to this manual pertains to the IG3000E open frame model. Careful observance of the instructions contained in this manual will result in safe and quality service work. All information, illustrations, directions and specifications included in this publication are based on the latest product information available at the time of approval for printing. WUXI KIPOR POWER CO., LTD, reserves the right to make changes without incurring any obligation whatever.

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No part of this publication may be reproduced without written permission.

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CONTENTS PREFACE .................................................................................................................... i. CONTENTS ................................................................................................................. 1 1. SPECIFICATIONS/WIRING DIAGRAM ................................................................... 3 1.1 SPECIFICATIONS............................................................................................ 3 1.2 PERFORMANCE CHARACTERISTICS........................................................... 4 1.3 PERFORMANCE CURVES.............................................................................. 5 1.4 DIMENSIONAL DRAWING .............................................................................. 6 1.5 WIRING DIAGRAMS ........................................................................................ 7 2. SERVICE INFORMATION ....................................................................................... 9 2.1 THE IMPORTANCE OF PROPER SERVICING ............................................... 9 2.2 IMPORTANT SAFETY PRECAUTIONS ........................................................... 9 2.3 SERVICE RULES........................................................................................... 10 2.4 ELECTRICAL PRECAUTIONS ...................................................................... 10 2.5 SERIAL NUMBER AND BARCODE ............................................................... 11 2.6 MAINTENANCE STANDARDS ...................................................................... 12 2.7 TORQUE VALUES ......................................................................................... 13 3. TROUBLESHOOTING ........................ 14 3.1 GENERAL SYMPTOMS AND CAUSES ......................................................... 14 3.2 HARD STARTING .......................................................................................... 15 3.3 IGNITION SYSTEM FAULT ............................................................................ 16 3.4 OIL SWITCH DEFECTIVE ............................................................................. 18 3.5 ENGINE WONT STAY RUNNING ................................................................. 18 3.6 ENGINE SPEED DOES NOT STABILIZE ...................................................... 19 3.7 SMART THROTTLE ....................................................................................... 19 3.8 LOW OR NO AC OUTPUT ............................................................................. 20 3.9 NO DC OUTPUT ............................................................................................ 21 3.10 NO ELECTRIC START ................................................................................. 22 3.11 BATTERY WONT CHARGE OR HOLD A CHARGE .................................... 22 4. MAINTENANCE ................................................................................................... 23 4.1 MAINTENANCE SCHEDULE ......................................................................... 23 4.2 ENGINE OIL ................................................................................................... 23 4.3 LOW ENGINE OIL ALARM INSPECTION ...................................................... 25 4.4 AIR FILTER .................................................................................................... 26 4.5 SPARK PLUG................................................................................................. 26 4.6 VALVE CLEARANCE ..................................................................................... 27 4.7 FUEL FILTER AND FUEL SWITCH ................................................................ 29 5. AIR FILTER AND MUFFLER ................................................................................ 30 5.1 AIR FILTER ...................................................................................................... 30 5.2 MUFFLER ........................................................................................................ 30 5.3 EXHAUST TUBE/SECONDARY AIR INJECTION VALVE................................ 31

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APPENDIX A- IG3000E ........................................................................................... 69 APPENDIX B- CAPCITOR ........................................................................................ 77

6. CARBURETOR .................................................................................................. 32 6.1 CARBURETOR REMOVAL AND REINSTALLATION ..................................... 32 6.2 STEPPING MOTOR DISASSEMBLY AND REASSEMBLY ............................ 33 6.3 CARBURETOR DISASSEMBLY AND REASSEMBLY ................................... 34 6.4 FLOAT AND STEPPING MOTOR INSPECTION ........................................... 35 7. CONTROL PANEL COMPONENTS .................................................................... 36 7.1 DISASSEMBLY AND REASSEMBLY ............................................................. 36 7.2 AC RECEPTACLES ....................................................................................... 36 7.3 DC RECEPTACLES ....................................................................................... 36 7.4 SMART THROTTLE SWITCH ........................................................................ 36 7.5 IGNITION MODULE ....................................................................................... 37 7.6 IGNITION SWITCH ........................................................................................ 37 7.7 BRIDGE RECTIFIER...................................................................................... 38 7.8 CHARGING REGULATOR ............................................................................. 38 8. HOUSING AND FUEL TANK .............................................................................. 39 8.1 DISASSEMBLY AND REASSEMBOY ............................................................ 39 8.2 VAPOR CONTROL SYSTEM ......................................................................... 40 9. RECOIL STARTER/AIR CONDUCT COVER ....................................................... 41 9.1 DISASSEMBLY AND REASSEMBLY ............................................................. 41 9.2 RECOIL STARTER INSPECTION AND ASSEMBLY ...................................... 42 10. ALTERNATOR/TRIGGER/IGNITION COIL/STARTER ..................................... 45 10.1 ALTERNATOR .............................................................................................. 45 10.2 IGNITION COIL AND TRIGGER .................................................................. 47 10.3 STARTER MOTOR....................................................................................... 50 11. VALVE COVER AND CYLINDER HEAD .............................................................. 51 11.1 VALVE COVER DISASSEMBLY/REASSEMBLY .......................................... 52 11.2 CYLINDER HEAD ASSEMBLHY .................................................................. 51 11.3 INSPECTION................................................................................................ 54 12. CRANKCASE/ CRANKSHAFT/CAMSHAFT/ PISTON ........................................ 56 12.1 CRANKCASE COVER ................................................................................. 56 12.2 CRANKSHAFT AND CAMSHAFT ................................................................ 57 12.3 PISTON AND CONNECTING ROD.............................................................. 58 12.4 INSPECTION ............................................................................................... 59

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______________________________________________________________________

1. SPECIFICATIONS
1.1 SPECIFICATIONS

_________________________________________________________________________________________________________

Dimensions and weights Model Length Width Overall height Net weight Engine Model Type KG205GETi IG3000 28.5 in (725mm) 17.9 in (455mm)

4-stroke,overhead valve, single cylinder

Displacement in (cc 12.0 (196) Bore x stroke in.(mm) Horsepower Compression ratio Cooling system Ignition system Ignition timing Spark plug Carburetor Air cleaner Governor Lubrication system Oil capacity Starting system

2.68 x 2.13 (6854)

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Forced air

T.C.I

25 B.T.D.C WR7DC

Float type, horizontal butterfly valve Semi-dry Electronic control Forced splash .63 qt (0.6L) Recoilr and Electrical starter

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4.0 @ 3600 rpm

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124.3lbs, 60kg

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21.6 in (548mm)

Stopping system Fuel

electron ground Automotive unleaded gasoline

Model Maximum output watts/amps Rated output watts/amps Rated output DC Rated frequency Rated voltage AC Rated Voltage DC Rated current AC Rated current DC Power factor Voltage variation rate- Momentary Average Average time Voltage stability Frequency variation rate Momentary Average time Frequency stability Insulation resistance AC circuit protector DC circuit protector Fuel tank capacity Fuel consumption g/KW.h rated load Operating hours at rated load Noise level dBA @ 23 (7M)

IG3000 3000/25 Amps 2800/23 Amps 60W 60 HZ 120V 12V 23.3A 5A 1.0cos 10%max. 1.5%max. 3 sec. max. 1% 1%max. 1%max. 1 sec. max. 0.1% 10M min. 26A(120V) 7A 11.6L 395

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7.0 Hours 63-69

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1.2 Performance

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Alternator Model Generator type Generator structure Excitation Voltage regulation system Phase Rotating direction Frequency regulation

KD 35 Pole rotation magnetic field type Self-ventilation drip-proof type Self-excitation (Magnet type) PWM (Plush width modulation) single phase Clockwise (Viewed from the generator) AC-DC-AC conversion (Inverter type)

1.3 PERFORMANCE CURVES The curves show performance of the generator under average conditions. Performance may vary to some degree depending on ambient temperature and humidity. The output voltage will be higher than usual when the generator is still cold, immediately after the engine starts. AC external characteristic curve

AC output voltage

120

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A Curren A

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(V)

240

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AC output voltage

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Current A 0

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110

1.4 DIMENSIONAL DRAWING Unit: mm

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1.5 WIRING DIAGRAMS a. Pre 2011 models

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b. Beginning 2011

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2. SERVICE INFORMATION
______________________________________________________________________ 2.1 The importance of proper servicing Proper servicing is essential to the safety of the operator and the reliability of the generator. Any error or oversight made by the technician while servicing can easily result in faulty operation and/or damage to the equipment or injury to the operator.

2.2 Important safety precautions

Be sure that the engine is off before you begin any maintenance or repairs. This will reduce the possibility of several hazards: - Carbon monoxide poisoning from engine exhaust: - Run engine in the ventilated place whenever . - Burns from hot parts. -Touch the engine parts after it cooled. - Injury from moving parts. Do not run the engine unless the instructions tell you to do so. Keep your hands and clothing away from rotating parts.

Read the instructions before you begin, and be sure you have the tools and skills required to perform the tasks safely.

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Be sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and safety equipment. When performing maintenance or repairs, be especially careful of the following:

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Could not follow the maintenance instruction and safety precautions can cause an unsafe condition that can lead to serious injury or death. Follow the procedures and precautions in this shop manual carefully.

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Some of the most important precautions are stated below. But we could not list all the potential danger, you should judge yourself if it need to do the maintenance task.

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Improper servicing can cause an unsafe condition that can lead to serious injury or death. Follow the procedures and precautions in this shop manual carefully.

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To reduce the possibility of fire or explosion, exercise extreme caution when working around gasoline. Use only a nonflammable solvent, not gasoline, to clean parts. Keep cigarettes, sparks and flames away from all fuel-related parts.

2.3 Service rules Use genuine KIPOR or KIPOR-recommended parts and lubricants or their equivalents. Parts that do not meet Kipors design specifications may damage the engine. Use the special tools designed for the product. Always install new gaskets, O-rings, etc. when reassembling components. When tighten the bolt or nut, please from major diameter to minor diameter, from inside to outside. Tighten the bolt and nut to the specific torque in this way.

After reassembly, check all parts for proper installation and operation. Many screws used in this machine are self-tapping. Be aware that cross-threading or over tightening these screws will strip the threads and ruin the hole. Use only metric tools when servicing this engine. Metric bolts, nuts and screws are not interchangeable with non metric fasteners. The use of incorrect tools and fasteners will damage the engine.

2.4 Electrical precautions Hold the connector body to disconnect the connector. Do not disconnect by pulling the wire harness. To disconnect the locking connector, be sure to unlock first, and then disconnect. Check the connector terminals for bend, excessive extrusion, missing terminals, or other abnormalities before connecting the connector. To connect, insert the connector as far as it goes. If the connector is a locking type, be sure that it is locked securely. Check the connector cover for breakage and check whether the connector female terminal is not opened excessively. Then, connect the connector securely. Check the connector terminal for rust. Remove the rust using an emery paper or equivalent 10

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Be sure to follow the mark and instruction of the book when use the tools.

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Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.

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material before connecting the connector. Set the harness clips in the specified places of the frame securely, and secure the wire harnesses. Clamp the cables securely. Clamp the wire harnesses securely so that they do not interfere with the rotating parts, moving parts and hot parts. Route and connect the wire harnesses properly. Be sure that the harnesses are not slack, twisted or pulled overly taut.

Engine serial number

Engine serial number

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The engine serial number is stamped on the engine block to the left of the oil drain bolt. Refer to this number when ordering parts or making technical inquiries.

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Serial number location

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When using an electrical tester like a volt/ohm meter or clamp on meter, read the manufacturers operating instructions carefully before operating the tester. Be sure that the tester battery is fully charged and the meter is functioning properly

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If a wire harness must contact the end of the bolts or screws or sharp edges and corners, protect the contact part of the harness with a loom or by winding with electrical insulating tape. If the wire harness has a grommet, set the grommet securely. Take care not to pinch the wire harnesses during installation of a part. If a wire harness has damaged insulation, repair by winding with electrical insulating tape.

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Route the wire harnesses properly so that they do not contact sharp edges and corners and the end of the bolts and screws on the body.

2.6 Maintenance standards Engine Part Item

Engine Cylinder Piston Piston pin Piston ring Max. speed under zero load (rpm) Sleeve I.D. Skirt O.D Piston-to-cylinder clearance Pin bore I.D. O.D Pin-to-piston clearance Ring width Top Second Ring side clearance Top/second Ring end clearance Top/second Small end I.D Big end I.D Big end oil clearance Big end side clearance Crank pin O.D. Valve clearance

Standard in. (mm)

3600100 0.45MPa/600rpm 2.67~2.68 (68.02~68.04) 2.68~2.68 (67.97~67.99) (0.030~0.070) 18.002~18.008 .708~.709 (17.990~18.000) .0001~.0071 (0.002~0.018) 1.420~1.440 1.420~1.440 0.02~0.06 0.150~0.350 .7089~.7093 (18.006~18.017) 1.182 (30.015~30.025) .0018~.0024 (0.046~0.060) .0177~.0276 (0.45~0.70) 29.960~29.975 0.060.02 0.080.02 5.45~5.48 5.45~5.47 0.020~0.052 0.030~0.062 0.8~1.2

Service limit

2.68 (68.17) 2.68 (67.62) .0047 (0.12) 18.042 .709 (17.95) .0003 (0.080) 1.32 1.32 0.15 1.0 0.711 (18.07) 1.184 (30.07) 0.12 .0394 (1.0) 29.90

Crankshaft

Valve

Carburetor Spark plug Ignition coil Pulse coil (Trigger) Starting relay

Generator
Part Ignition coil Outer charging winding coil Inner charging winding coil Sub winding coil Main winding coil Item Resistance Resistance Resistance Resistance Resistance Type Yellow/GreenGreen Blue-Blue Purple-purple WhiteWhite BlackBlack Standard 120V 240V 0.26~0.28 0.26~0.28 0.12~0.15 0.19~0.21 0.12~0.14 0.8~1.1 0.12~0.15 0.19~0.21 0.12~0.14 33-35 Service limit

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Cylinder block

Valve lifter I.D. Camshaft Bearing I.D. Floater height Clearance Resistance Primary side Second side Air gap Resistance Resistance

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Crankcase cover

Camshaft Bearing

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Camshaft Valve lifter

O.D O.D

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Valve spring Cam wheel

Free Length Cam height I.D

Intake/Exhaust Intake/Exhaust

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Intake Exhaust Valve rod OD Intake Exhaust Vessel I.D Intake/Exhaust Clearance of valve and vessel Intake Exhaust Seat width Intake/Exhaust

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Connecting rod

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1.20 (30.5) 1.09~1.10 (27.63~27.91) 1.09~1.10 (27.68~27.94) .550~.551 (13.966~13.984) .313~.314 (7.96~7.98) >550~.552 (14.000~14.027) .315~.316 (8.0008.015) .550~.552 (14.00014.027) 14 0.70.8 0.81.3 1521k .020~.030 (0.50.75) 80130 3.84.1

.211 (5.35) .211 (5.35) .219 (5.56) .0039 (0.1) .0047 (.12) .079 (2.0) 1.14 (29) 1.08 (27.34) 1.08 (27.34) .553 (13.92) .310 (7.87) .553 (14.05) .317 (8.06) .553 (14.05)

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2.7 Torque values

Item Connecting rod bolt Cylinder cover bolt Spark plug Crankcase cover Flywheel nut Tightening bolt of rocker arm base Adjusting nut of rocker axis Thread dia. X pitch M7 M860 M141.2519 M830 M141.5 M816 M60.75 M5 boltnut Standard torque M6 boltnut M8 boltnut M10 boltnut Tightening torque Ft/lbf 10.3~11.8 20.7~23.6 18.4~22.2 14.75~17.0 59.0~66.42 14.75~17.0 7.4~8.8 4.4~5.9 N.m 14~16 28~32 25~30 20~23 80~90 20~23 10~12 6~8

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Note Use standard torque values for fasteners that are not listed in this table.

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40.6~44.3

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14.8~17.0

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5.9~7.4

8~10 20~23 55~60

______________________________________________________________________

3. TROUBLESHOOTING
______________________________________________________________________
3.1 General symptoms and possible causes Symptom Cause(s) Fuel filter clogged Fuel tank tube clogged Fuel switch clogged Carburetor failure Spark plug cap disconnected Ignition coil failure Trigger failure Spark plug failure Oil level switch (Low oil alarm) failure Igniting device failure Igniting winding failure Remedy Clean Clean Clean Clean and/or replace* Install securely Inspect and replace

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Choke air inlet not controlled properly Engine speed does not stabilize, too high or too low

Inverter unit failure

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Throttle control motor (stepping motor) failure Valve clearance misadjusted

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Carburetor failure

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* Carburetor replacement parts are not available. No adjustments or overhaul is permitted under current EPA/CARB guidelines.

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Engine does not start or hard starting

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Adjust

Inspect and replace Inspect and replace Inspect and replace Inspect and replace Inspect and replace

The position can be full open or half open Adjust and/or disassemble and clean Inspect and replace Inspect and replace

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3.2 Hard starting If the engine does not start or is hard starting after reassembly, check to see whether the throttle valve is at the full open position.

Cylinder compression check 1. Remove the spark plug cap and spark plug 2. Install a compression gauge in the spark plug hole. Pull the recoil starter rope several times with force and measure the cylinder compression.

Cylinder compression

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0.45Mpa/600rpm

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3.3 Ignition system fault Fill oil to the specified location before inspecting Please use the WR7DC spark plug check the spark plug 1. Remove the spark plug. 2. Install the spark plug onto spark plug cap. 3. Turn the ignition switch of engine to the position ON. Then ground the spark electrode to the cylinder head cover and pull the start motor rope to check if sparks jump across the electrode.

Keep sparks and any other combustible source away from the spark plug hole.

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Make sure no spilled fuel is anywhere on the engine and no fuel is on the spark plug

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Do not pull the recoil starter rope while touching the high tension wire with a wet hand. High voltage is generated which is dangerous. Be sure to ground the spark plug and hold the plug cap with an insulated pair of pliers to perform the spark test.

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Measure the spark plug gap and perform the spark plug Gap: 0.6~0.8 mm 0.7-0.8mm No spark Perform the spark test again using a new spark plug No spark Perform test using a new portfire No spark Good spark Replace the portfire Good spark Replace the spark plug

Normal Inspecting the resistance value Abnormal and the clearance of trigger Normal Inspecting resistance value of ignition coil and high tension cable and insulation of high tension cap Inspecting and repair or replace

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Abnormal

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Replace the trigger or adjust the clearance of trigger

Replace the ignition coil

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Inspecting the resistance value Abnormal of alternator ignition coil

Replace the stator of alternator

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No spark

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Disconnect low oil alarm and Good spark perform spark plug test

Replace the oil level switch

3.4 Engine oil level is low, but engine does not stop (defective oil switch)

3.5 Engine starts but wont stay running

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3.6. Engine speed does not increase or stabilize. (smart throttle is in right position)
Check the air cleaner Not clogged Check the valve clearance Normal Remove the spark plug and Abnormal Clean electrodes and adjust the check the electrodes for carbon spark plug gap or replace a new and spark plug gap. spark plug Normal Abnormal Readjust valve gap Clogged Clean the air cleaner

Normal Check the cylinder compression Normal Perform the throttle control system troubleshooting

3.7 Smart throttle problems

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1.Engine speed is too high, hunting or too low.

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Abnormal Check if the gap of valve is correct. Check if it exists too much carbon in combustion chamber. Check the piston, piston ring and cylinder for wear and damage.

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Check for paper cushion of air intake and heat insulation of carburetor

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Abnormal Tighten the nuts securely or install a new carburetor heat insulator or gasket.

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Not clogged

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Check for blockage of the main jet and holes of carbunetor

Clogged

Disassemble and clean

2. Smart Throttle system does not work under no load (engine speed does increase after connecting load with Smart Throttle system ON).

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3.8 Low or no AC output

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3.9 No DC Output

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3.10 No Electric Start

3.11 Battery will not hold a charge

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______________________________________________________________________

4. MAINTENANCE
______________________________________________________________________ 4.1 Maintenance schedule Regular service period Perform at every indicated month or operating hour interval, whichever comes first Engine Oil Check Replace Air cleaner Check Clean Spark plug Clean-Adjust Spark arrestor Clean Valve clearance Check-Adjust Fuel tank and Clean filter Fuel lines Check Note: Each use First month Every 3 Every 6 or 20 Hrs. months months or 50Hrs. or 100 Hrs. Every year or 300 Hrs.

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A. Checking Oil Level Engine should be shut off and generator placed on level ground when checking the oil level. (1) Remove the oil dipstick, check oil level.

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4.2 Engine Oil

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Interval operating time in normal troubleshooting. When used in dusty conditions, filter should be cleaned every 10 hours. Maintenance should be carried out by the qualified technicians. PLEASE READ KIPOR OPERATION MANUAL.

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upper limit

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lower limit Screw the oil stick tightly,then unscrew it

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Every 2 years (Replace if necessary)

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(2) B. (1) (2)

Add the proper viscosity engine oil to the upper limit if oil level is low. Be careful to over fill. Changing engine oil Remove the oil dipstick and unscrew oil drain plug to drain used oil. Replace the drain plug and secure tightly.

(3) Refill the oil (oil capacity 0.6L) Recommend engine oil: SE, SF engine oil classified by API or SAE10W-30 engine oil which same as SG grade. Use SAE10W-30 engine oil when the temperature is below 10. Use SE, SF engine oil classified by API or SAE5W-30 engine oil which same as SG grade when the temperature is below -15. (4) Add the proper viscosity oil to the upper oil limit level.

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Discharge oil quick and thorough when the engine is hot, but the temperature is not too hot, prevent scalding. Please send the discarded oil to maintenance station or recycle centre. Dont pour the discarded oil into earth or waste.

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(5)

Reinstall the dipstick and screw it tightly

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4.3 Inspection of the Low Oil Alarm (1) Disconnect the orange connection of the low oil alarm wire when engine is running, and ground one end to the engine block as shown below to ensure that the engine will stop when the low oil alarm lamp is light. NOTE: On early models, the low oil alarm connection is in the back of the generator on the opposite side of the service door.

Lead of oil alarm

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(2) Stop the engine and disconnect the orange wire of the low oil alarm after insuring that the engine oil is at the proper level. Test the conductivity between the end shown in the figure and the case of engine, No conductivity indicates a normal condition.

Lead of oil alarm

(3) Drain all the engine oil in the engine repeat the test. The switch is working properly if there is normal conductivity.

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Ground through the case of engine

Lead of ignitor

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Lead of ignitor

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4.4 Air Filter (1) Open the service door. (2) Open the cover of air filter and take out the filter element. (3) Blow the inner side of filter element using compressed air or lightly knock it to remove dirt. If any dirt remains, change the element. Be sure to use a genuine Kipor element to maintain a proper seal and avoid engine damage. (4) Reinstall the filter element and close the service door.

! Attention !

4.5 Spark Plug

(1) Remove the spark plug cap and use a spark plug wrench to remove the spark plug. (2) Remove carbon or other deposits with a stiff wire brush. Check if the sealing washer is damaged. (3) Check the resistance of the spark plug and replace it if it is not within the specified resistance value. Resistance of spark plug 3~9K

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Dirty air filter will affect the air into the carburetor, and reduce engine power. Dont operate the generator without the filter element in place or serious engine damage may result.

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Blow the innerr side of air filter element using the compressed air

Filter element subassembly Air filter cover

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(4) Use a feeler gauge to check the electrode gap. Adjust the electrode to the following specification by carefully bending the side electrode to the specified value. Clearance of spark plug Standard spark plug

4.6 Adjusting valve clearance

! Attention !

Valve adjustment should only be performed on a cool engine. (1) Remove cylinder cover bolt, cylinder cover, cylinder cover gasket.

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(5) Reinstall the spark plug and screw it tightly after regulating, the specified torque is 20~30 N.

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0.7-0.8

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0.7~0.8mm

Gasket of cylinder head cover

cylinder head cover

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If the intake valve is in the START position, please pull the starter again when align the scale of starting wheel with the sign on the air guiding cover.

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(3) Insert a feeler gauge into the gap between rocker and valve to measure the valve clearance. Intake 0.060.02mm Exhaust.0.080.02mm

Valve Clearance

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scale

! A ttention !

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(2) Pull the starter rope gently and set the piston in top dead center (the scale of starting wheel should align with the sign on the air guiding cover)

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(4) If adjustment is necessary, proceed as follows: a. Hold rocker axis with the wrench and loosen the lock nut. b. Loosen the lock nut of rocker axis to gain the specified intake and exhaust valve clearance. c. Hold rocker axis with a wrench and tighten the lock nut.

4.7 Fuel filter and fuel switch

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Make sure that there is no leaking fuel after service. (1) Drain all fuel from the tank and carburetor and remove the fuel tank. (2) Loosen the nuts between fuel switch and fuel tank and remove the filter element. (3) Turn the fuel switch to the open position. Clean it with a suitable solvent then blow dry with compressed air. (4) Remove any foreign material from the fuel filter and insure the filter net is undamaged. Replace if necessary (5) Properly install seal cushion and filter element and tighten the nuts between fuel switch and the fuel tank.

Keep smoking materials and any open flames away during fuel system maintenance.

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! Attention !

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Filter seal cushion Fuel element Fuel switch

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Fuel tank

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d. Check the clearance of valve after adjustment.

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______________________________________________________________________

5.

Air Filter and Muffler

5.1 Air filter Disassembly and assembly

5.2 Muffler Disassembly and assembly

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5.3 Air outlet pipe, second air valve assembly (EPA 2011 and CARB models)
Secondary Air Injection Valve Secondary Air Injection Valve Gasket

Muffler

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Spark Arrestor

Muffler elbow

6Carburetor
! Attention !
Drain fuel from carburetor bowl before removal and disassembly Smoking and any source of combustion are strictly forbidden in the process of disassembly. 6.1 Carburetor removal and reinstallation

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Reassembly Check if there is any damage in the gasket before assembly

plate Air Choke choke weldment

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Carburetor gasket A

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Choke knob and cable Rope of air choke

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Air intake pipe gasket Reassembly Check if there is any damage in the gasket before assembly

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Gasket of carburetor

Carburetor Insulator block of assembly carburetor Reassembly Carburetor gasket B Check if there is any Reassembly damage in the insulator Check if there is any block before assembly. damage in the gasket before assembly

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Filter element Air filter cover

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Air filter bottom case

6.2 Stepping motor disassembly and reassembly

stepping motor

stepping motor base fork spring when removing or disassembly Take care hold it tightly for spring, fear that reinstalling for It the is spring easily will lose when it is disassemblied . st, dropped or flies out of position. If lo cut a length from a ball point pen. fork spring

fork

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fuel control lever

fork

6.3 Carburetor disassembly and reassembly

NOTE: With the exception of changing the main jet, no adjustments, modifications, or other maintenance is permitted on EPA and CARB certified engines. This includes any Kipor generator ever sold in North America. This drawing is for information only.

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6.4 Float and stepping motor inspection Floater height Place the carburetor as fig. and measure the size between floater and body.(floater height) Specified height 14mm

If the floater height dont meet the specified height, please replace.

Stepping motor

Measuring the resistance of stepping motor leading wires Specified resistance 1 and 345~55 2 and 445~55

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Replace the stepping motor if the resistance value exceeds the specified range.

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7.

CONTROL PANEL, CHARGING REGULATOR AND INVERTER UNIT

7.1 Disassembly and assembly

7.4 Smart Throttle switch There should be continuity with the switch ON, no continuity with the switch OFF.

7.3 DC receptacle Use a length of wire to make the hole behind the receptacle short circuit. Insert two test leads into the output holes to test the circuit. If the circuit is open, push the reset button on the panel and recheck. If the circuit remains open, change the DC receptacle. Newer models have a 5A fuse in the receptacle. Check that first.

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7.2 AC receptacle If no AC power, first check for continuity between the terminals on the receptacle and the red and black wires going to the inverter module. See the wiring diagram. Check the contacts for discoloration or evidence of burning.

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Component Inspection

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7.5 Ignition Module Pull the 10 pin connector plug(10P) from the ignition module. Connect an ohm meter to ground and measure the resistance in the various 10P connector pins to measure the resistance. Use the following chart for reference: Color Blue Orange Yellow Kelly Green Red Circuit unit Primary ignition coil Low oil alarm Trigger coil Ground wire Ignition power coil winding Engine ignition cutoff switch Specified resistance value 0.8~1.3 It is not lit under the condition that oil position is normal 80~130 continuity

Blue Orange Yellow Kelly Green Red

7.6 Ignition switch

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Check the connection between each terminal pair, the results should agree with the following table, otherwise replace the switch.

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1
O FF O N

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3 2 5

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4
3 4 5
S TA R T

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The Ignition switch is put through when it switches on, otherwise it will disconnect.

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0.26~0.28

7.7 Bridge rectifier mode of a multimeter to test connection between each group. The results Use the must agree with standard listed in the following table. Positive lead Negative lead 1 2 3 4 Connect Connect Connect Connect Block

2 Block

3 Block Block

4 Block Block

4AC terminal ()

7.8 Charging Regulator

DC charging voltage
output anode(gray) AC inputpurple

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Start the engine and disconnect the wire of charging adjustor with the two battery terminals. Measure the voltage between output terminal of charging adjustor and grounding wire. If no output, check the AC input from the stator (purple wires).

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3Negative terminal (+)

13~14V

GroundingKelly AC inputpurple

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1Negative terminal (-) 2AC terminal ()

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Block

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Connect

8. HOUSING GROUP AND FUEL TANK

8.1 Disassembly and installation

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8.2 Vapor Control System (CARB Models)

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9. Recoil starter, Air conduct cover

9.1 Disassembly and Reassembly

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9.2 Recoil starter assembly Note: this section is primarily for information. Kipor no longer provides replacement parts for the recoil starter.

(2) Smear lubrication grease on the starter outer shell claw, install the starter reel. Revolve the reel anticlockwise to hang the spring inner hook on the starter outer shell claw.

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(1) Set the spring into the starter reel, and hang the spring outer hook inside the reel groove.

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(5) Install the revolving axis, revolving axis parts and friction spring, Fix it with bolts.

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(4) Pull out the rope from from starter outer shell hole completely, pass it through the handle and make a figure 8 knot, then turn over the handle cover. Loosen the reel to rebound the spring taking care not to allow the reel to pop out.

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(3) Make a figure 8 knot at one end of the rope, pass the other end through the reel hole. Wind the reel anticlockwise 6 turns to set the reel.

(6) Pull the starter several times, checking for proper operation.

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10. Alternator, ignition coil, trigger, starter motor

10.1 Alternator A. Disassembly, installation

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B. Inspection 1Ignition winding Measure the resistance between green wire and olive wire Resistance value 0.26~0.28

Resistance value 5Main winding

Measure the resistance between three black wires.

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Resistance value

120V 0.8~1.1

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0.12~0.14

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4Sub winding Measure the resistance between two white wires.

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Resistance value

0.19~0.21

230/240V 3.3~3.5

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3Inner charge winding Measure the resistance between two purple wires.

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Resistance value

0.12~0.15

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2Outer charge winding Measure the resistance between two blue wires.

10.2 Ignition coil and trigger A. Disassembly and reassembly

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B. Inspection (1) Ignition coil . With an ohmmeter check the resistance between the two wires going to the coil primary resistance 0.8~1.3

(2Trigger Test the resistance between the trigger wires. Resistance of trigger 80~130

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Sub resistance

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Check resistance between one end of primary ignition coil terminals and spark plug cap to measure sub resistance of ignition coil. 15~21K

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C. Adjustment: Note: trigger clearance or air gap on 2008 models onward is fixed. Adjust the clearance between the trigger and rotor. clearance of trigger 0.020~0.030 in. (0.50~0.75mm)

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Insert the gauge between the projection on the trigger and the rotor to measure the clearance. If it is not within the specified range, readjust the trigger to the recommended clearance. Alternate tightening of the bolts turn at a time until completely tight.

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10.3 Starter Motor Removal and reinstallation

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11Valve Cover and Cylinder Head

11.1 Valve cover disassembly and reassembly

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11.2 Cylinder head assembly

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11.3 Inspection Valve spring length Standard(mm) 30.5 Service limit(mm) 29

Valve seat width Standard(mm) 0.8-1.2

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Service limit(mm) 2.0

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Cylinder head Remove all accumulated carbon in and remaining gasket material on the valve cover mounting surface. Check for cracks around spark plug holes, valve guides valve seats. Check for distortion of the cylinder head with a ruler and feeler gauge. Service limit Replace if greater than 0.1mm,

Standard mm Air intake Air outlet 5.46~5.48 5.45~5.47

Service limit (mm) 5.35 5.35

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External diameter of valve stem

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Inner diameter of valve seat Standard mm Air intake/outlet 5.500~5.512 Service limit (mm) 5.56

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Clearance between valve stem and valve guide

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Air intake Air outlet

Standard mm 0.020~0.052 0.030~0.062

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Service limit (mm) 0.10 0.12

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12Crankcase, Crankshaft, Piston

12.1 Crankcase cover

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12.2 Crankshaft and camshaft

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Alignment of time setting marks Align and install of comparison marks of camshaft and time setting gear (small gear on camshaft).

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12.3 Piston
Manufacture mark

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Piston ring installation Caution Put the manufacturer mark facing up when installation; Pay attention to the installation positions of 1st and 2nd ring. Check if the piston ring can rotate freely when installation. All openings of piston ring should be kept away from the direction of piston pin with 120 degree angle.

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Low oil alarm inspection 1Lift the low oil alarm and measure the conductivity between lead wire and copper grounding piece using instrument. 2Convert the low oil alarm and measure again, it should be not conductive. 3Dip the low oil alarm into engine oil in order to inspect float, and measure again, it should be not conductive.

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12.4 Inspection

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Noise and moving of shaft Clean and dry the shaft, rotate the shaft manually and check the free gap; if any noise or moving, replace the shaft.

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68.02~68.04

68.17

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Standard mm

Service limit (mm)

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Inner diameter of cylinder

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 External diameter of the apron of piston Standard mm 67.97~67.99 Service limit (mm) 67.62

10mm

Clearance between piston and cylinder Standard mm 0.030~0.070 Service limit (mm)

Side clearance of piston

0.020~0.060

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Standard mm

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Service limit (mm) 0.150

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0.120

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 Terminal clearance of piston ring Fix the piston ring in cylinder using the top part of piston and measure the terminal clearance of piston.

Standard mm 0.150~0.350

Service limit (mm) 1.0

Width of piston ring

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Standard mm

The first ring The first ring

1.420~1.440 1.420~1.440

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Service limit (mm) 1.320 1.320

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 External diameter of piston pin Standard mm 17.990~18.000 Service limit (mm) 17.950

Internal diameter of piston pin bore Standard mm 18.002~18.008 Service limit (mm) 18.042

Clearance between piston pin and pin bore Standard mm 0.002~0.018 Service limit (mm) 0.080

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 Internal diameter of the small terminal of connecting rod

Standard mm 18.006~18.017

Service limit (mm) 18.070

Internal diameter of the large terminal of connecting rod Standard mm 30.015~30.025 Service limit (mm)

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30.070

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 External diameter of journal Standard mm 29.960~29.975 Service limit (mm) 29.900

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0.45~0.70

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Standard mm

Service limit (mm) 1.0

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Clearance of side face of big endof the connecting rod

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Clearance of oil film of big end of connecting rod 1Remove the engine oil on the surface of journal. 2Set plastic line gauge on the journal and install the connecting rod. Tighten the bolt according to specified torque. Pay attention not to rotate the crankshaft when tightening. Tightening torque: 14~16N.m. 3Remove the connecting rod and measure the thickness of plastic line gauge. 4 If clearance exceeds service limit, please replace the connecting rod, and then measure the clearance again. If the clearance still exceeds service limit after changing a new rod, please polish the crankshaft journal and use the connecting rod that is less than standard value or replace the crankshaft. Standard mm 0.046~0.060 Service limit (mm) 0.120

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 Height of camshaft Standard mm Service limit (mm) Air intake Air outlet 27.63~27.91 27.68~27.94 27.34 27.34

External diameter of camshaft Standard mm 13.966~13.984

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Service limit (mm) 13.920

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Inner diameter of bearing of camshaft Standard mm 14.000~14.027 Service limit (mm) 14.050

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APPENDIX A: IG3000E
This appendix regarding the IG3000E is intended to supplement the IG3000 generator and engine service manual. The basic construction and operation of this generator is similar and differs only in the frame, fuel tank, and control panel.

Contents
A1. SPECIFICATIONS............................................................................................... 70 A2. PERFORMANCE ................................................................................................ 71 A3. DIMENSIONAL DRAWING ................................................................................. 72 A4. SERIAL NUMBER LOCATION ............................................................................ 73 A5 WIRING DIAGRAM .............................................................................................. 74 A6 CONTROL PANEL, CHARGING ADJUSTER, INVERTER MODULE .................. 75 A7 FRAME AND FUEL TANK .................................................................................... 21

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A1. SPECIFICATIONS
Dimensions and weight Model Length Width Overall height Net weight Engine Model Type Displacement Bore x stroke (mm) Horsepower Compression ratio Cooling system Ignition system Ignition timing Spark plug Carburetor Air cleaner Governor Lubrication system Oil capacity Starting system Stopping system Fuel Fuel tank capacity KG205GEXi IG3000E 18.9 in. (491mm) 15.75 in. (410mm) 20.6 in. (425mm) 77 lbs. (36kg)

2.68 x 2.13 (68 x 54 mm)

Forced air

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T.C.I

25 B.T.D.C F7RTC Float type, horizontal butterfly valve Semi-dry Electronic control Splash

.63 qt. (0.6L) Recoil starter /Recoil starter and Electrical starter Primary circuit ground Automotive unleaded gasoline 87 octane 4.0 Gal (15.1 L)

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4.0 @ 3600 rpm

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11.96 cu. In.(196 cc)

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4 cycle, overhead valve, single cylinder

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Alternator Model Generator type Generator structure Excitation Voltage regulation system Phase Rotating direction Frequency regulation

KD 35 Multi pole rotation type Self-ventilation drip-proof type Self-excitation (Magnet type) PWM (Pulse Width Modulation) Three phase (single phase output) Clockwise (viewed from the generator end) AC-DC-AC conversion (Inverter type)

Model Maximum output (AC) Rated output (AC) Maximum Current Rated current (AC) Rated frequency Rated voltage (AC) Rated voltage (DC) Rated current (DC) Power factor Voltage variation rate- Momentary Average Average time Voltage stability Frequency variation rate -Momentary -Average -Average time Frequency stability Insulation resistance AC circuit protector DC circuit protector Operating hours at rated load Noise level

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IG3000Ei 3.0 KVA 2.8 KVA 25 A 23.3 A 60 HZ 120V 12V 8.3 A 1.0 5 %max. 1.5 %max. 3 sec. max. 1%

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.5 %max. .5 %max. 1 sec. max. 0.1% 10M min. 26A(120V) 14A 5.6 Hours 65~70 dB @ 23 (7m)

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A2. PERFORMANCE

A3. DIMENSIONAL DRAWINGS

Unit : mm

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A4. SERIAL NUMBER LOCATION

The engine serial number is stamped on the block to the left of the oil drain bolt. Use this number when ordering parts or making other inquiries.

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A5. Wiring Diagram

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A6. Control Panel, Charging Adjustor and Inverter Module

Disassembly and assembly

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A7. Frame and Fuel Tank

Disassembly and Reassembly

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APPENDIX B: CAPACITOR
In all models built between December 2007and ending in December 2010, a capacitor was added to reduce electro-mechanical interference and eliminate problems with some digital clocks not displaying the time properly. The capacitor is attached directly to the frame behind the control panel to the left of the inverter module.

RECEPTACLE CONNECTION TO CAPACITOR

CONNECTION TO RECEPTACLES
2. TROUBLESHOOTING AND TESTING

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Do not touch the exposed terminals nor attempt to take any measurements before discharging the capacitor

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Terminals

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Check the capacitor when troubleshooting issues regarding digital clock displays. Should the capacitor fail, there will be no impairment of any other generator function or output. As the capacitor is connected directly to the output power supply, it has the potential to store a high voltage charge and should be discharged prior to testing. Unplug the 2p connector and short circuit the capacitor by placing the end of an insulated screwdriver across the two terminals.

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CAPACITOR INSTALLATION

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Use the capacitance checking mode of a multimeter. Replace the capacitor if any reading is outside the standard value of 10uF5%.

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